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Operating Instructions Radiation-based sensor for level detection POINTRAC 31 8/16 mA/HART - four-wire With SIL qualification Document ID: 43388 Contents Contents About this document 1.1 Function ........................................................................................................................... 4 1.2 Target group ..................................................................................................................... 4 1.3 Symbolism used ............................................................................................................... 4 2 For your safety 2.1 Authorised personnel ....................................................................................................... 5 2.2 Appropriate use ................................................................................................................ 5 2.3 Warning about incorrect use............................................................................................. 5 2.4 General safety instructions ............................................................................................... 5 2.5 CE conformity................................................................................................................... 5 2.6 NAMUR recommendations .............................................................................................. 6 2.7 Environmental instructions ............................................................................................... 6 3 Product description 3.1 Configuration .................................................................................................................... 7 3.2 Principle of operation........................................................................................................ 8 3.3 System limitations ............................................................................................................ 8 3.4 Packaging, transport and storage ..................................................................................... 9 3.5 Accessories and replacement parts ............................................................................... 10 3.6 Corresponding source container .................................................................................... 10 4 Mounting 4.1 General instructions ....................................................................................................... 12 4.2 Mounting instructions ..................................................................................................... 13 5 Connecting to power supply 5.1 Preparing the connection ............................................................................................... 16 5.2 Connection ..................................................................................................................... 19 6 Functional safety (SIL) 6.1 Objective ........................................................................................................................ 21 6.2 SILqualification .............................................................................................................. 21 6.3 Application area ............................................................................................................. 21 6.4 Safety concept of the parameterization .......................................................................... 22 7 Set up with the display and adjustment module 7.1 Insert display and adjustment module ............................................................................ 24 7.2 Adjustment system ......................................................................................................... 25 7.3 Parameter adjustment .................................................................................................... 25 7.4 Saving the parameter adjustment data ........................................................................... 36 8 Setup with PACTware 8.1 Connect the PC .............................................................................................................. 37 8.2 Parameter adjustment with PACTware ............................................................................ 38 8.3 Saving the parameter adjustment data ........................................................................... 39 9 Diagnostics and service 9.1 Maintenance .................................................................................................................. 40 9.2 Status messages............................................................................................................ 40 9.3 Rectify faults ................................................................................................................... 43 9.4 Exchanging the electronics module ................................................................................ 44 9.5 Software update ............................................................................................................. 45 2 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 1 Contents 9.6 How to proceed in case of repair .................................................................................... 45 10 Dismounting 10.1 Dismounting steps.......................................................................................................... 46 10.2 Disposal ......................................................................................................................... 46 43388-EN-131119 11 Supplement 11.1 Technical data ................................................................................................................ 47 11.2 Dimensions .................................................................................................................... 51 Safety instructions for Ex areas PleasenotetheEx-specificsafetyinformationforinstallationandoperation in Ex areas. These safety instructions are part of the operating instructions manual and come with the Ex-approved instruments. Editing status: 2013-11-11 POINTRAC 31 • 8/16 mA/HART - four-wire 3 1 About this document 1 About this document 1.1 Function 1.2 Target group 1.3 Symbolism used This operating instructions manual provides all the information you need for mounting, connection and setup as well as important instructionsformaintenanceandfaultrectification.Pleasereadthisinformation before putting the instrument into operation and keep this manual accessible in the immediate vicinity of the device. This operating instructions manual is directed to trained specialist personnel. The contents of this manual should be made available to these personnel and put into practice by them. Information, tip, note This symbol indicates helpful additional information. Caution: If this warning is ignored, faults or malfunctions can result. Warning: If this warning is ignored, injury to persons and/or serious damage to the instrument can result. Danger: If this warning is ignored, serious injury to persons and/or destruction of the instrument can result. • → 1 Ex applications This symbol indicates special instructions for Ex applications. List The dot set in front indicates a list with no implied sequence. Action This arrow indicates a single action. Sequence of actions Numbers set in front indicate successive steps in a procedure. Battery disposal This symbol indicates special information about the disposal of batteries and accumulators. 43388-EN-131119 4 POINTRAC 31 • 8/16 mA/HART - four-wire 2 For your safety 2 2.1 For your safety Authorised personnel All operations described in this operating instructions manual must be carried out only by trained specialist personnel authorised by the plant operator. During work on and with the device the required personal protective equipment must always be worn. 2.2 Appropriate use The POINTRAC 31 is a sensor for point level detection. Youcanfinddetailedinformationontheapplicationrangeinchapter "Product description". Operational reliability is ensured only if the instrument is properly usedaccordingtothespecificationsintheoperatinginstructions manual as well as possible supplementary instructions. 2.3 Warning about incorrect use 2.4 General safety instructions Inappropriate or incorrect use of the instrument can give rise to application-specifichazards,e.g.vesseloverfillordamagetosystem components through incorrect mounting or adjustment. This is a state-of-the-art instrument complying with IEC 61508 and all prevailing regulations and guidelines. The instrument must only be operatedinatechnicallyflawlessandreliablecondition.Theoperator is responsible for the trouble-free operation of the instrument. During the entire duration of use, the user is obliged to determine the compliance of the necessary occupational safety measures with the current valid rules and regulations and also take note of new regulations. The safety instructions in this operating instructions manual, the corresponding Safety Manual, the national installation standards as well as the valid safety regulations and accident prevention rules must be observed by the user. For safety and warranty reasons, any invasive work on the device beyond that described in the operating instructions manual may be carried out only by personnel authorised by the manufacturer. Arbitraryconversionsormodificationsareexplicitlyforbidden. 43388-EN-131119 The safety approval markings and safety tips on the device must also be observed. 2.5 CE conformity ThedevicefulfillsthelegalrequirementsoftheapplicableECguidelines.ByaffixingtheCEmarking,VEGAconfirmssuccessfultesting of the product. POINTRAC 31 • 8/16 mA/HART - four-wire 5 2 For your safety Only with class A instruments: The device is a class A instrument designed for use in an industrial environment.Whenusedinadifferentenvironment,e.g.,inaliving area, the electromagnetic compatibility must be ensured by the user. If necessary, suitable screening measures against conducted and emitted disturbances must be taken. Youcanfindtheconformitycertificateinthedownloadsectionunder www.vega.com. 2.6 NAMUR recommendations NAMUR is the automation technology user association in the process industry in Germany. The published NAMUR recommendations are acceptedasthestandardinfieldinstrumentation. ThedevicefulfillstherequirementsofthefollowingNAMURrecommendations: • • • • NE 21 – Electromagnetic compatibility of equipment NE 43 – Signal level for malfunction information from measuring transducers NE53–Compatibilityoffielddevicesanddisplay/adjustment components NE107–Self-monitoringanddiagnosisoffielddevices For further information see www.namur.de. 2.7 Environmental instructions Protection of the environment is one of our most important duties. That is why we have introduced an environment management system with the goal of continuously improving company environmental protection.Theenvironmentmanagementsystemiscertifiedaccording to DIN EN ISO 14001. Pleasehelpusfulfillthisobligationbyobservingtheenvironmental instructions in this manual: • • Chapter "Packaging, transport and storage" Chapter "Disposal" 43388-EN-131119 6 POINTRAC 31 • 8/16 mA/HART - four-wire 3 Product description 3 Type plate Product description 3.1 Configuration Thenameplatecontainsthemostimportantdataforidentificationand use of the instrument: 1 11 9 2 3 4 5 6 10 9 9 7 8 Fig. 1: Layout of the type label (example) 1 2 3 4 5 6 7 8 9 10 Serial number Instrument type Product code Electronics Protection rating Process and ambient temperature, process pressure Instrument length Hardware and software version Order number Serial number of the instrument ID numbers, instrument documentation The type label contains the serial number of the instrument. With it youcanfindthefollowingdataonourhomepage: • • • • • • Product code of the instrument (HTML) Delivery date (HTML) Order-specificinstrumentfeatures(HTML) Operating instructions at the time of shipment (PDF) Order-specificsensordataforanelectronicsexchange(XML) Testcertificatepressuretransmitters(PDF) Go to www.vega.com, "VEGA Tools" and "Serial number search". Asanalternative,youcanfindthedataviayourSmartphone: 43388-EN-131119 • • • Scope of this operating instructions manual Download the smartphone app "VEGA Tools" from the "Apple App Store" or the "Google Play Store" Scan the Data Matrix code on the type label of the instrument or Enter the serial number manually in the app This operating instructions manual applies to the following instrument versions: • Hardware from 1.0.6 POINTRAC 31 • 8/16 mA/HART - four-wire 7 3 Product description • • Electronics versions Theinstrumentisavailableindifferentelectronicsversions.Eachversioncanbeidentifiedviatheproductcodeonthetypelabel: • Scope of delivery Application area Software from 1.6.0 Modificationstatuselectronicsfrom-07 StandardelectronicstypePT30E-XX The scope of delivery encompasses: • • • Radiation-based sensor Mounting accessory Documentation – this operating instructions manual – Safety Manual (SIL) PROTRAC series 30 (Document-ID 42961) – Operating instructions manual "Display and adjustment module" (optional) – Ex-specific"Safety instructions" (with Ex versions) – ifnecessary,furthercertificates 3.2 Principle of operation The instrument is suitable for applications in liquids and bulk solids in vesselsunderdifficultprocessconditions.Thereareapplicationpossibilities in nearly all areas of industry. The limit level is detected contactlessly through the vessel wall. Neitheraprocessfittingnoravesselopeningisrequired.Theinstrument isthusidealforretrofitting. Functional principle In radiation-based measurement, a Caesium-137 or Cobalt-60 isotope emits focussed gamma rays that are attenuated when penetratingthevesselwallandthemedium.ThePVTdetectorontheopposite side of the tank receives the radiation. When the intensity of the radiationdropsbelowadefinedvalue,e.g.duetodamping,thenthe POINTRAC 31 switches. The measuring principle has proven itself well under extreme conditions because it measures contactlessly from outside through the vessel wall. The measuring system ensures maximum safety, reliability and plant availability independent of the medium and its properties. 3.3 System limitations Thereareseveralmeasuringprinciple-specificfactorswhichcaninfluence the measuring result. Keep these factors in mind in order to fully utilize the capabilities of the instrument with respect to measurement certainty and reproducibility. 8 The implemented radioactive isotope and its activity must be selected according to the properties of the vessel and the medium. The necessary radioactive activity must be calculated on the basis of the plant data. POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Activity of the source 3 Product description To this end, make use of our planning service for an optimum layout of the measurement and selection of the isotope. This applies particularly to SIL applications. Due to the physical properties of the radioactive radiation, the pulse rateissubjecttoslightfluctuations.Setasuitabledampingleveltoget a stable measured value. Non-linearity of the process value The relation between level and the pulse rate measured by the sensor is not linear. External radiation Externalradiationsourcescaninfluencethemeasuredvalue(e.g. welding joint tests). In safety-relevant applications, the safety function must be treated as unreliable as long as the external radiation occurs. Set up a linearization table to get a linear level signal. For precise mesurement results, make sure when setting up the linearization tablethattheactualfillingheightofthemeasuringpointsisenteredas exactly as possible. If necessary, you must take measures to maintain the safety function. Span Make sure during the planning that for the planned application, a possiblylargedifferentofthepulseratewithemptyandfullvesselis reaced. This applies mainly for products with low density or in vessels with extremely small diameter. Packaging Your instrument was protected by packaging during transport. Its capacity to handle normal loads during transport is assured by a test based on ISO 4180. 3.4 Packaging, transport and storage 43388-EN-131119 The packaging of standard instruments consists of environmentfriendly, recyclable cardboard. For special versions, PE foam or PE foil is also used. Dispose of the packaging material via specialised recycling companies. Transport Transport must be carried out in due consideration of the notes on the transport packaging. Nonobservance of these instructions can cause damage to the device. Transport inspection The delivery must be checked for completeness and possible transit damage immediately at receipt. Ascertained transit damage or concealed defects must be appropriately dealt with. Storage Up to the time of installation, the packages must be left closed and stored according to the orientation and storage markings on the outside. Unless otherwise indicated, the packages must be stored only under the following conditions: • • • • Not in the open Dry and dust free Not exposed to corrosive media Protected against solar radiation POINTRAC 31 • 8/16 mA/HART - four-wire 9 3 Product description Storage and transport temperature PLICSCOM • • • Avoiding mechanical shock and vibration Storage and transport temperature see chapter "Supplement Technical data - Ambient conditions" Relative humidity 20 … 85 % 3.5 Accessories and replacement parts The display and adjustment module PLICSCOM is used for measured value indication, adjustment and diagnosis. It can be inserted into the sensor or the external display and adjustment unit and removed at any time. Youcanfindfurtherinformationintheoperatinginstructions"Display and adjustment module PLICSCOM" (Document-ID 27835). VEGACONNECT TheinterfaceadapterVEGACONNECTenablestheconnectionof communication-capable instruments to the USB interface of a PC. For parameter adjustment of these instruments, the adjustment software PACTwarewithVEGA-DTMisrequired. Youcanfindfurtherinformationintheoperatinginstructions"Interface adapter VEGACONNECT" (Document-ID 32628). VEGADIS 81 TheVEGADIS81isanexternaldisplayandadjustmentunitforVEGA plics® sensors. For sensors with double chamber housing the interface adapter "DISADAPT"isalsorequiredforVEGADIS81. Youcanfindfurtherinformationintheoperatinginstructions"VEGADIS 81" (Document-ID 43814). External indicating unit TheVEGADIS62issuitableformeasuredvalueindicationofsensors. It is looped into the 4 … 20 mA/HART signal cable. Youcanfindfurtherinformationintheoperatinginstructions"VEGADIS 62" (Document-ID 36469). Electronics module TheelectronicsmodulePT30E.XXisareplacementpartforradiationbased sensors POINTRAC 31. TheelectronicsmodulecanonlybeexchangedbyVEGAservice technician. 3.6 Corresponding source container A radioactive isotope in a suitable source holder is the prerequisite for a radiation-based measurement setup. In Germany, for example, the current radiation protection ordinance (StrlSchV)basedontheAtomicEnergyLaw(AtG)applies. The following points are important for measurement with radiationbased methods: 10 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 The handling of radioactive substances is regulated by law. The radiation protection rules of the country in which the system is operated applyfirstandforemost. 3 Product description Handling permit A handling permit is required for operation of a system using gamma rays.Thispermitisissuedbytherespectivegovernmentofficeorthe responsibleauthority(inGermany,forexample,officesforenvironmental protection, trade supervisory boards, etc.) Youcanfindfurtherinstructionsintheoperatinginstructionsmanual of the source container. General instructions for radiation protection When handling radioactive sources, unnecessary radiation exposure must be avoided. An unavoidable radiation exposure must be kept as low as possible. Take note of the following three important measures: 1 2 3 Fig. 2: Measures for protection against radioactive radiation 1 2 3 Shielding Time Distance Shielding: Provide good shielding between the radioactive source and yourself as well as all other persons. Special source containers (e.g.VEGASOURCE)aswellasallmaterialswithhighdensity(e.g. lead,iron,concrete,etc.)provideeffectiveshielding. Time: Stay as short a time as possible in radiation exposed areas. 43388-EN-131119 Distance: Your distance to the source should be as large as possible. The local dose rate of the radiation decreases in proportion to the square of the distance to the radiation source. Radiationsafetyofficer Theplantoperatormustappointaradiationsafetyofficerwiththe necessary expert knowledge. He is responsible that the radiation protection ordinance is maintained and that all radiation protection measures are implemented. Control area Control areas are areas in which the local dose rate exceeds a certain value.Onlypersonswhoundergoofficialdosemonitoringareallowed intothesecontrolareas.Youcanfindtherespectivelyvalidlimitvalues for control areas in the guideline of the respective authority (in Germany, for example, the radiation protection ordinance). We are at your disposal for further information concerning radiation protection and regulations in other countries. POINTRAC 31 • 8/16 mA/HART - four-wire 11 4 Mounting 4 Switchoffsource Mounting 4.1 General instructions The source container is part of the measuring system. In case the source container is already equipped with an active isotope, the source container must be locked before mounting. Danger: Before mounting; make sure that the source is securely closed. Use a padlock to secure the source container in the closed condition and prevent it from being inadvertently opened. Protection against moisture Protect your instrument against moisture penetration through the following measures: • • • Use the recommended cable (see chapter "Connecting to power supply") Tighten the cable gland Loop the connection cable downward in front of the cable gland This applies particularly to: • • • Outdoor mounting Installations in areas where high humidity is expected (e.g. through cleaning processes) Installations on cooled or heated vessels Suitability for the process Make sure that all parts of the instrument exposed to the process are conditions suitable for the existing process conditions. These are mainly: • • • Active measuring component Processfitting Process seal • • • • Process pressure Process temperature Chemical properties of the medium Abrasionandmechanicalinfluences Process conditions are particularly: Youcanfindthespecificationsoftheprocessconditionsinchapter "Technical data" as well as on the nameplate. Protective caps In the case of instrument housings with self-sealing NPT threads, it is not possible to have the cable entries screwed in at the factory. The openings for the cable glands are therefore covered with red protective caps as transport protection. The suitable cable glands and blind plugs come with the instrument. 12 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Prior to setup you have to replace these protective caps with approved cable glands or close the openings with suitable blind plugs. 4 Mounting Installation position 4.2 Mounting instructions Note: Along with the planning, our specialists will analyse the conditions of the measurement loop to dimension the radiation source (isotope) accordingly. You get a "Source Sizing" document specifying the required source activity and containing all relevant mounting information for your measuring point. You must follow the instructions of this "Source Sizing" document in addition to the following mounting instructions. The following mounting information is applicable as long as there is nothingelsespecifiedinthe"SourceSizing"document. 2 1 Fig. 3: Mounting position - level detection 1 2 Vertical mounting Mounting horizontally, at right angles to container Youcanfindinformationonprotectivebarriersandthemounting of the corresponding source container in the operating instructions manualofthesourcecontainer,e.g.VEGASOURCE. 43388-EN-131119 For level detection, the sensor is generally mounted horizontally at the height of the requested limit level. Make sure that there are no struts or reinforcements at this position in the vessel. Direct the exit beam of the source container exactly towards the measuring range of POINTRAC 31. Fasten the sensor in such a way that it cannot fall out of the holder. If necessary, provide the sensor with a support from below. Mount the source container and POINTRAC 31 as close as possible to the vessel. If there are gaps, secure the area with a safety fence POINTRAC 31 • 8/16 mA/HART - four-wire 13 4 Mounting and protective grating so that no one can reach into the dangerous area. Sensor orientation Level detection - max. detection The POINTRAC 31 is suitable for level detection in liquids or bulk solids. It is mounted at the height of the requested switching point. Fig. 4: POINTRAC 31 as max. level detection (uncovered) Level detection - min. detection 14 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Fig. 5: POINTRAC 31 as min. level detection (covered) 4 Mounting Bulk solids with low density Fig. 6: POINTRAC 31 as level detection (top view) POINTRAC 31 lends itself well for level detection of bulk solids with low density. Mount the instrument horizontally at the height of the requested switching point. MountthesourcecontainerVEGASOURCEdisplacedby90°inorder to get the widest possible radiation angle. When the sensor is covered by the medium, the radiation damping is considerably stronger - hence, the switching point is all the more reliable. Protection against heat If the max. ambient temperature is exceeded, you must take suitable measures to protect the instrument against overheating. You can protect the instrument by providing a suitable insulation against the heat or mounting the instrument further away from the heat source. Make sure these measures are taken into account already in the planning stage. If you want to carry out such measures later on, contact our specialists to ensure that the accuracy of the application is not impaired. Ifthesemeasuresarenotsufficienttomaintainthemax.ambient temperature, you could consider using the water cooling system we offerforPOINTRAC31. 43388-EN-131119 The water cooling must also be included in the calculations for the measuring point. Contact our specialists regarding the dimensioning of the water cooling. POINTRAC 31 • 8/16 mA/HART - four-wire 15 5 Connecting to power supply 5 Safety instructions Voltage supply via mains voltage Connecting to power supply 5.1 Preparing the connection Always keep in mind the following safety instructions: • • Connect only in the complete absence of line voltage If overvoltage surges are expected, overvoltage arresters should be installed In this case, the instrument is designed in protection class II. To maintain this protection class, it is absolutely necessary that the ground conductor be connected to the internal ground terminal. Take note of the general installation regulations. Supply voltage and current signal are carried on separate connection cables if reliable separation is required. The supply voltage range can differdependingontheinstrumentversion. Thedataforpowersupplyarespecifiedinchapter"Technical data". Select connection cable For power supply, an approved installation cable with PE conductor is required. The 8/16 mA current output is connected with standard two-wire cable without screen. If electromagnetic interference is expected which is above the test values of EN 61326 for industrial areas, screened cable should be used. Use cable with a round wire cross section. An outer cable diameter of6…12mm(0.24…0.47in)ensuresthesealeffectofthecable entry.Ifcablewithadifferentdiameterorwirecrosssectionisused, exchange the seal or use an appropriate cable connection. Unused cableentryglandsdonotprovidesufficientprotectionagainstmoisture and must be replaced with blind plugs. Cable entry Generally provide all unused cable entries with suitable blind plugs. The thin foam rubber washers in the cable glands only serve as a dust cover during transport. Cable gland ½ NPT In the case of instrument housings with self-sealing NPT threads, it is generally not possible to have the cable glands screwed in at the factory. The openings for the cable glands are therefore covered with red protective caps as transport protection. Before setup you have to replace these protective caps with approved cable glands or close the openings with suitable blind plugs. Unused cableglandsdonotprovidesufficientprotectionagainstmoistureand must be replaced with blind plugs. The suitable cable glands and blind plugs come with the instrument. 16 If screened cable is necessary, connect the cable screen on both ends to ground potential. In the sensor, the screen must be connected directly to the internal ground terminal. The ground terminal on the outside of the housing must be connected to the potential equalisation (low impedance). POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Cable screening and grounding 5 Connecting to power supply If potential equalisation currents are expected, the connection on the processing side must be made via a ceramic capacitor (e. g. 1 nF, 1500V).Thelow-frequencypotentialequalisationcurrentsarethus suppressed,buttheprotectiveeffectagainsthighfrequencyinterference signals remains. Warning: Significantpotentialdifferencesexistinsidegalvanizationplantsas well as on vessels with cathodic corrosion protection. Considerable equalisationcurrentscanflowoverthecablescreenifthescreenis grounded on both ends. To avoid this, the cable screen in such applications must be connected only on one end to ground potential in the switching cabinet. The cable screen must not be connected to the inner ground terminal in the sensor and the outer ground terminal on the housing must not be connected to potential equalization! Information: The metal parts of the instrument are conductively connected with the inner and outer ground terminal on the housing. This connection is either a direct metallic connection or, in case of instruments with external electronics, a connection via the screen of the special connection cable. Youcanfindspecificationsonthepotentialconnectionsinsidethe instrument in chapter "Technical data". Connection technology The voltage supply and signal output are connected via the springloaded terminals in the housing. The connection to the display and adjustment module or to the interface adapter is carried out via contact pins in the housing. Connection procedure Proceed as follows: The procedure applies to instruments without explosion protection. 1. Unscrew the big housing cover 2. Loosen compression nut of the cable entry 3. Remove approx. 10 cm (4 in) of the cable mantle, strip approx. 1 cm (0.4 in) of insulation from the ends of the individual wires 43388-EN-131119 4. Insert the cable into the sensor through the cable entry POINTRAC 31 • 8/16 mA/HART - four-wire 17 5 Connecting to power supply 1 Fig. 7: Connection steps 4 and 5 1 Locking of the terminal blocks 5. Insertasmallslottedscrewdriverfirmlyintotherectangularlock openings of the respective connection terminal 6. Insert the wire ends into the round openings of the terminals according to the wiring plan Information: Solidcoresaswellasflexiblecoreswithcableendsleevesare inserteddirectlyintotheterminalopenings.Incaseofflexiblecores without end sleeves, press the rectangular lock opening with a small screwdriver; the terminal opening is freed. When the screwdriver is released, the terminal opening closes again. 7. Check the hold of the wires in the terminals by lightly pulling on them Toloosenaline,insertasmallslottedscrewdriverfirmlyintothe rectangular locking opening according to the illustration 8. Connect the screen to the internal ground terminal, connect the outer ground terminal to potential equalisation 10. Screw the housing cover back on Theelectricalconnectionishencefinished. 18 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 9. Tighten the compression nut of the cable entry gland. The seal ring must completely encircle the cable 5 Connecting to power supply Information: The terminal blocks are pluggable and can be detached from the electronics. For this purpose loosen the two lateral locking levers of the terminal block with a small screwdriver. When loosening the locking, the terminal block is automatically squeezed out. It must snap in place when re-inserted. 5.2 Non-Ex instruments and instruments with non-intrinsically safe current output 6 /N 2 PE 4 5 2 6 9 4 12 11 10 11 3 22 21 20 19 18 17 16 15 14 13 12 1 1 /L 22 1 Electronics and connection compartment - Non-Ex instruments and instruments with nonintrinsically safe current output Connection 5 Fig. 8: Electronics and connection compartment with non-Ex instruments and instruments with non-intrinsically safe current output 1 2 3 4 5 6 Voltage supply Relay output Signal output 8/16 mA/HART active Signal output 8/16 mA/HART Multidrop passive Interface for sensor-sensor communication (MGC) Setting the bus address for sensor-sensor communication (MGC)1) Adjustment and connection compartment - Non-Ex instruments and instruments with nonintrinsically safe current output 2 43388-EN-131119 5 6 7 8 1 Fig. 9: Adjustment and connection compartment with non-Ex instruments and instruments with non-intrinsically safe current output 1 2 1) Terminals for the external display and adjustment unit Contact pins for the display and adjustment module or interface adapter MGC = Multi Gauge Communication POINTRAC 31 • 8/16 mA/HART - four-wire 19 5 Connecting to power supply 4 /N 2 22 21 20 19 18 17 16 15 14 13 12 1 1 /L 22 1 Electronics and connection compartment - Instruments with intrinsically safe current output Instruments with intrinsically safe current output Youcanfinddetailedinformationontheexplosion-protectedversions (Ex-ia,Ex-d)intheEx-specificsafetyinstructions.Thesesafety instructions are part of the scope of delivery and come with the Exapproved instruments. PE 4 5 2 3 6 12 11 Fig. 10: Electronics and connection compartment (Ex-d) with instruments with intrinsically safe current output 1 2 3 4 Voltage supply Relay output Interface for sensor-sensor communication (MGC) Setting the bus address for sensor-sensor communication (MGC)2) Adjustment and connection compartment - Instruments with intrinsically safe current output 2 3 (+)1 2(-) 1 5 6 7 8 4 Fig. 11: Adjustment and connection compartment (Ex-ia) with instruments with intrinsically safe current output 1 2) 20 MGC = Multi Gauge Communication POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 2 3 4 Terminals for intrinsically safe signal output 8/16 mA/HART (Multidrop) active (not on versions with Ex-d approval) Contact pins for the display and adjustment module or interface adapter Terminals for the external display and adjustment unit Ground terminal 6 Functional safety (SIL) 6 Functional safety (SIL) 6.1 Objective In case of dangerous outages, processing facilities and machines can cause risks for persons, environment and property. The risk of such outages must be judged by the plant operator. Dependent thereon are measures for risk reduction through error prevention, error detection and fault control. The part of plant security depending on the correct functioning of safety-related components for risk reduction is called functional safety. Components used in such safety-instrumented systems (SIS) must therefore execute their intended function (safety function) with a definedhighprobability. The safety requirements for such components are described in the international standard IEC 61508, which sets the measure for unique and comparable judgement of instrument safety and hence contributes to worldwide legal certainty. Depending on the degree of required risk reduction, we distinguish between four safety levels, from SIL1 for low risk to SIL4 for very high risk (SIL = Safety Integrity Level). 6.2 SILqualification Additional characteristics When developing instruments which can be used in safety-instruand requirements mented systems, the focus is on avoiding systematical as well as determining and controlling random errors. Here the most important characteristics and requirements from the perspective of functional safety according to IEC 61508: • • • • • • Internal monitoring of safety-relevant circuit parts Extended standardization of the software development In case of failure, switching of the safety-relevant outputs to a definedsafestatus Determinationofthefailureprobabilityofthedefinedsafetyfunction Reliable parameterization with non-safe user environment Recurring function test TheSILqualificationofcomponentsisspecifiedinamanualforfunctionalsafety(SafetyManual).Here,youcanfindallsafety-relevant characteristics and information required by the user and planner for planning and operating the safety-relevant system. This document is attached to each instrument with SIL rating and can be also retrieved via the serial number search on our homepage. 43388-EN-131119 6.3 Application area The instrument can be used for level detection or level measurement of liquids and bulk solids in a safety-related system according to IEC61508.TakenoteofthespecificationsintheSafetyManual. The following inputs/outputs are permitted: • Relay output POINTRAC 31 • 8/16 mA/HART - four-wire 21 6 Functional safety (SIL) • Tool for operation and parameterization 4 … 20 mA current output 6.4 Safety concept of the parameterization The following tools are permitted for parameterization of the safety function: • • The integrated display and adjustment unit for on-site adjustment The DTM suitable for the signal conditioning instrument in conjunction with an adjustment software according to the FDT/DTM standard, e. g. PACTware Note: For operation of the POINTRAC 31 the DTM Collection version 1.67.2 orhigherisrequired.Themodificationofsafety-relevantparametersis only possible with active connection to the instrument (online mode). Reliable parameterization To avoid possible errors during parameterization in a non-safe user environment,averificationprocedureisusedthatmakesitpossible to detect parameterization errors reliably. For this, safety-relevant parametersmustbeverifiedbeforetheyarestoredinthedevice.In normal operating condition, the instrument is also locked against parameter changes through unauthorized access. This concept applies to the adjustment on the instrument but also to adjustment with PACTware with DTM. Safety-relevant parameters For protection against unwanted or unauthorzed adjustment, the set parameters must be barred from unauthorized access. For this reason, the instrument is shipped in locked condition. The PIN in delivery status is "0000". Whenshippedwithaspecificparameteradjustment,theinstruments are accompanied by a list with the values deviating from the basic setting. By entering the serial number, the list is available as a download under "www.vega.com/VEGA-Tools". Afterachange,allsafety-relevantparametersmustbeverifiedand confirmedviaacharacterstringcomparison. The parameter settings of the measurement loop must be documented. For this purpose, the document "SIL device settings" is attached to each instrument listing all safety-relevant parameters in the shipping status as well as containing free space for own notes. This document is also available on our homepage. In addition, a list of the safety-relevant parameters can be stored and printed via PACTware/ DTM. For each parameter change, the instrument must be unlocked via a PIN (see chapter "Setup steps - Lock adjustment"). The device status is indicated by the symbol of an unlocked or locked padlock. Unsafe device status Warning: If adjustment is enabled, the safety function must be considered as unreliable. This applies until the parameterization is terminated correctly. If necessary, other measures must be taken to maintain the safety function. 22 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Release adjustment 6 Functional safety (SIL) Change parameter All parameters changed by the operator are marked automatically so thattheycanverifiedinthenextstep. Verify parameters/Lock adjustment FortheverificationthePINmustbeenteredfirstandacomparisonof twocharacterstringsmustbecarriedout.Theusermustconfirmthat both character strings are identical, this is used to check the characterrepresentationandthecommunicationchannels.Theverification texts are provided in German and with all other menu languages in English. Inasecondstep,allmodified,safety-relevantparametersarelisted, whichmustallbeconfirmed.Afterthisprocessisfinished,theinstrument will be locked automatically and the safety function is guaranteed again. Warning: If the described process was not carried out completely or correctly (e.g. interruption or voltage loss), the instrument remains in the released and hence unsafe status. Instrument reset Warning: In case of a reset to basic settings, all safety-relevant parameters will also be reset to default. Therefore all safety-relevant parameters must be checked or readjusted. 43388-EN-131119 Incomplete process POINTRAC 31 • 8/16 mA/HART - four-wire 23 7 Set up with the display and adjustment module 7 Mount/Dismount display and adjustment module 7.1 Set up with the display and adjustment module Insert display and adjustment module The display and adjustment module can be inserted into the sensor and removed again at any time. It is not necessary to interrupt the power supply. Proceed as follows: 1. Unscrew the small housing cover 2. Place the display and adjustment module in the desired position ontheelectronics(youcanchooseanyoneoffourdifferentpositions-eachdisplacedby90°) 3. Press the display and adjustment module onto the electronics and turn it to the right until it snaps in. 4. Screw housing cover with inspection window tightly back on Removal is carried out in reverse order. The display and adjustment module is powered by the sensor, an additional connection is not necessary. 1 2 Fig. 12: Insert display and adjustment module 24 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Note: Ifyouintendtoretrofittheinstrumentwithadisplayandadjustment module for continuous measured value indication, a higher cover with an inspection glass is required. 7 Set up with the display and adjustment module 7.2 Adjustment system 1 2 Fig. 13: Display and adjustment elements Key functions 1 2 LC display Adjustment keys • [OK] key: – Move to the menu overview – Confirmselectedmenu – Edit parameter – Save value • • • 43388-EN-131119 Adjustment system [-] key: – Presentation, change measured value – Select list entry – Select editing position [+] key: – Change value of the parameter [ESC] key: – Interrupt input – Jump to next higher menu The device is adjusted via the four keys of the display and adjustment module. The LC display indicates the individual menu items. The functions of the individual keys are shown in the above illustration. Approx. 60 minutes after the last pressing of a key, an automatic reset to measuredvalueindicationistriggered.Anyvaluesnotconfirmedwith [OK] will not be saved. 7.3 Parameter adjustment The instrument is adapted to the application conditions via the parameter adjustment. The parameter adjustment is carried out with an adjustment menu. POINTRAC 31 • 8/16 mA/HART - four-wire 25 7 Set up with the display and adjustment module Lock setup - adjustment With this menu item you safeguard the sensor parameters against unauthorizedorunintentionalmodifications. To avoid possible errors during parameterization in a non-safe user environment,averificationprocedureisusedthatmakesitpossible to detect parameterization errors reliably. For this, safety-relevant parametersmustbeverifiedbeforetheyarestoredinthedevice.In normal operating condition, the instrument is also locked against parameter changes through unauthorized access. For this reason, the instrument is shipped in locked conditon. The PIN in the delivery status is "0000". Afterachange,allsafety-relevantparametersmustbeverified.For this purpose, a character string comparison must be carried out. This is used to check the character respresentation and the communication channels. Confirmifthetwocharacterstringsareidentical.Theverificationtexts are provided in German and with all other menu languages in English. Inasecondstep,allmodifiedsafety-relevantparametersarelisted. Confirmthemodifiedvalues. If the described process of parameter adjustment was run through completely and correctly, the instrument will be locked and hence ready for operation. Otherwise the instrument remains in the released and hence unsafe condition. Main menu Themainmenuisdividedintofivesectionswiththefollowingfunctions: 26 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Setup: Settings, e.g. for measurement loop name, isotope, application, background radiation, adjustment, signal output 7 Set up with the display and adjustment module Display: Settings, for example language, measured value display Diagnosis: Information, for example, of device status, peak value, simulation Additional adjustments: Instrument unit, reset, date/time, copying function Info: Instrument name, hardware and software version, date of manufacture, instrument features Procedure Check if the correct language is already set for the display. If not, you can change the language in the menu item "Display/Language". Start with the setup of POINTRAC 31. In the main menu point "Setup", the individual submenu points should be selected one after the other and provided with the correct parameters to ensure optimum adjustment of the measurement. The procedure is described in the following. Stick with the normal sequence of the menu items as closely as possible. Setup Setup - Measurement loop name In this menu item you can assign an unambiguous name to the sensor or the measurement loop. Setup/Isotope In this menu item you can adjust the POINTRAC 31 to the integrated isotope in the source container. This parameter is described in the operating instructions manual "Display and adjustment module". For this purpose, check which isotope is integrated in the source container.Youcanfindthisinformationonthetypelabelofthesource container. 43388-EN-131119 Through this selection, the sensitivity of the sensor is adapted perfectly to the isotope. The normal reduction of the emitter activity is hence considered through the radioactive decay. The POINTRAC 31 requires this information of the automatic decay compensation. This ensures an interference-free measurement over the complete life time of the gamma emitter - an annual recalibration is not necessary. Enter the requested parameters via the appropriate keys, save your settings with [OK] and jump to the next menu item with the [ESC] and the [->] key. POINTRAC 31 • 8/16 mA/HART - four-wire 27 7 Set up with the display and adjustment module Setup Setup - Application Enter here, the respective application. Setup - Background radiation Thenaturalradiationonearthinfluencestheaccuracyofthemeasurement. This menu item enables adaptation of the sensor to the requested application. Only the application "Point level" can be selected with your instrument. With this menu item the natural background radiation can be faded out. For this purpose, the POINTRAC 31 measures the natural background radiation and sets the pulse rate to zero. In the future, the pulse rate from this background radiation will be automatically deducted from the total pulse rate. This means: only the component of the pulse rate originating from the source will be displayed. The source container must be closed for this setting. Setup/Unit In this menu item you can select the temperature unit. Setup - Adjustment mode in this menu item you can select if you want to carry out a single or double point adjustment on the sensor. With the double point adjustment, the Delta I value is selected automatically. We recommend selecting the double point adjustment. To use this, you must be able to change the level of the vessel so as to carry out the adjustment of the sensor with full status (covered) and with empty status (uncovered). Hence, you will get a very reliable switching point. 28 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Withsinglepointadjustment,youhavetodefinethedifference between the min. and max. adjustment points (Delta I) yourself during the following setup. 7 Set up with the display and adjustment module Setup/Adjustment uncovered (single point adjustment) This menu item appears only if you have selected "Single point adjustment" as adjustment mode (Setup/Adjustment mode). In this menu item you determine the point at which the POINTRAC 31 should switch in uncovered status. Empty the vessel until the sensor is uncovered. For this enter the requested pulse rate manually or let the rate be determined by POINTRAC 31. Automatic determination of the pulse rate should be given preference. The pulse rate is entered in ct/s. This is the number of counts per second, i.e. the measured gamma radiation reaching the sensor. Prerequisites: • • Radiation is switched on - Source container is set to "ON" There is no medium between source container and sensor You can enter the value for "Adjustment uncovered" (ct/s) manually. You can have the value for "Adjustment uncovered" determined by POINTRAC 31. Setup/Delta I (single point adjustment) This menu item appears only if you have selected "Single point adjustment" as adjustment mode (Setup/Adjustment mode). In this menu item you can adjust at which percentage value of the max. pulse rate the sensor should switch over. 43388-EN-131119 Since in most cases the radiation is almost completely absorbed when the sensor is covered, the pulse rate when the sensor is covered is very low. Thechangebetweenthetwostatusesissufficientlyclear. Hence a percentage value of 90 % for the Delta I value is recommended. You select lower values for sensitive detection of material cones or buildup which cause only partial absorption of the radiation. POINTRAC 31 • 8/16 mA/HART - four-wire 29 7 Set up with the display and adjustment module Adjustment "covered" (two-point adjustment) This menu item appears only if you have selected under adjustment mode (setup/adjustment mode) the "Two-point adjustment". In this menu item you can set the min. pulse rate (ct/s) at which the sensor should switch over. Fill the vessel until the POINTRAC 31 is covered. You thus get the min. pulse rate (ct/s) for the "covered" adjustment. Enter the requested pulse rate manually or let the rate be determined by POINTRAC 31. Automatic determination of the pulse rate should be given preference. You can enter the adjustment point (ct/s) manually. You can let the adjustment point be determined by POINTRAC 31. Adjustment "uncovered" (two-point adjustment) This menu item appears only if you have selected under adjustment mode (setup/adjustment mode) the "Two-point adjustment". In this menu item you can set the max. pulse rate (ct/s) at which the sensor should switch over. Empty the vessel until the POINTRAC 31 is uncovered. You thus get the max. pulse rate (ct/s) for the "uncovered" adjustment. Enter the requested pulse rate manually or let the rate be determined by POINTRAC 31. Automatic determination of the pulse rate should be given preference. 30 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 You can enter the adjustment point (ct/s) manually. 7 Set up with the display and adjustment module You can let the adjustment point be determined by POINTRAC 31. Setup/Current output In this menu item you can activate or deactivate the current output. The POINTRAC 31 checks if with activated current output there is really an instrument connected. If no instrument is connected to the current output, you have to deactivate the current output. Setup/Current output mode In this menu item you can select the switching behaviour of the sensor. You can choose between an 8 - 16 mA characteristics or a 16 - 8 mA characteristics. Inthismenuitemyoucanalsodefinetheswitchingbehaviourincase of fault. You can select if the current output should output 22 mA or < 3.6 mA in case of fault. Setup/Relay In this menu item you can select which mode the sensor should operate in. Youcanchoosebetweenoverfillanddryrunprotection. The relay outputs of the sensor react accordingly. 43388-EN-131119 Overfillprotection=therelaywilldeenergise(safecondition)when the max. level is reached. Dry run protection = the relay will deenergise (safe condition) when the min. level is reached. Make sure that you have selected the correct characteristics. See menu item "Setup/Current output mode". POINTRAC 31 • 8/16 mA/HART - four-wire 31 7 Set up with the display and adjustment module Lock setup - adjustment With this menu item you safeguard the sensor parameters against unauthorizedorunintentionalmodifications. To avoid possible errors during parameterization in a non-safe user environment,averificationprocedureisusedthatmakesitpossible to detect parameterization errors reliably. For this, safety-relevant parametersmustbeverifiedbeforetheyarestoredinthedevice.In normal operating condition, the instrument is also locked against parameter changes through unauthorized access. For this reason, the instrument is shipped in locked conditon. The PIN in the delivery status is "0000". Afterachange,allsafety-relevantparametersmustbeverified.For this purpose, a character string comparison must be carried out. This is used to check the character respresentation and the communication channels. Confirmifthetwocharacterstringsareidentical.Theverificationtexts are provided in German and with all other menu languages in English. Inasecondstep,allmodifiedsafety-relevantparametersarelisted. Confirmthemodifiedvalues. If the described process of parameter adjustment was run through completely and correctly, the instrument will be locked and hence ready for operation. Display Display - Language 32 With this parameter you can change the display language. POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Otherwise the instrument remains in the released and hence unsafe condition. 7 Set up with the display and adjustment module This parameter is described in the operating instructions manual "Display and adjustment module". Display/Displayed value With this parameter you can change the indication of the display. You can choose if the display should show the actual pulse rate or the electronics temperature. Diagnostics Diagnostics - Device status In this menu item, you can enquire the status of your sensor. In normal operation, the sensor displays the message "OK". In case of fault, you willfindthecorrespondingfaultcodehere. This parameter is described in the operating instructions manual "Display and adjustment module". Diagnosis - Peak value The peak value function holds the max. and min. values during operation. This parameter is described in the operating instructions manual "Display and adjustment module". Diagnosis - Adjustment data Here, you can retrieve the adjustment value of the sensor. This is the percentage value of the max. pulse rate at which the sensor switches over. If you have carried out a single point adjustment, this is the entered value. With a two-point adjustment, this is the calculated value. The value is an indication for the reliability and reproducibility of the switching point. Thegreaterthedifferenceinthepulseratebetweencoveredand uncoveredstatus,thegreaterthedifferentialvalue(DeltaI)andthe more reliable the measurement. The automatically calculated damping is also oriented around the Delta I value. The higher the value, the lower the damping. A Delta I value below 10 % is an indication for a critical measurement. 43388-EN-131119 Diagnosis/Simulation In this menu item you can simulate measured values via the current output. This allows the signal path to be tested, e.g. through downstream indicating instruments or the input card of the control system. Youcansimulatedifferentvalues: POINTRAC 31 • 8/16 mA/HART - four-wire 33 7 Set up with the display and adjustment module Pulse rate of the sensor Current output Switching function of the relay Information: The simulation is automatically terminated 10 minutes after the last pressing of a key. Diagnosis - Calculated damping The sensor calculates a suitable integration time automatically. Additional adjustments Additional settings - PIN In this menu item, the PIN is permanently activated/deactivated. Thus you protect the sensor data against unauthorized access and unintended changes. The default setting of the PIN is 0000. This parameter is described in the operating instructions manual "Display and adjustment module". Additional adjustments Date Time In this menu item you can set the actual date and time. Additional adjustments/ Reset When a reset is carried out, all settings (with only a few exceptions) are reset. The exceptions are: PIN, language, SIL and HART mode. This parameter is described in the operating instructions manual "Display and adjustment module". 34 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 The following reset functions are available: 7 Set up with the display and adjustment module Basic settings: Resetting of the parameter adjustments to default valuesatthetimeofshipment.Order-specificsettingsaredeleted. Default settings: Resetting of the parameter adjustment like under "Basic settings". In addition, special parameters are reset to default values.Order-specificsettingsaredeleted. Peak values of measured value: Resetting of the parameter adjustments in the menu item "Setup" to the default values of the respective instrument.Order-specificsettingsremainbutarenottakenoverinto the current parameters. Peak values of temperature: Resetting of the measured min. and max. temperatures to the actual measured value. The following table shows the default values of the instrument. The values apply for the application "Level". First of all you have to select the application. Depending on the instrument version, not all menu items may be availableortheymaybedifferentlyassigned: Menu Menu item Default value Setup Measurement loop name Sensor Isotope Cs-137 Application Limit level 43388-EN-131119 Adjustment mode Single point adjustment Additional adjustments HART mode Adjustment - uncovered 90000 ct/s Adjustment - covered 9000 ct/s Delta I 90 % Background radiation 0 ct/s Temperature unit °C Damping Is calculated automatically by the instrument Current output mode 8/16 mA, < 3.6 mA Mode - Relay Overfillprotection only with two-point adjustment Block adjustment Released Display Language Selected language Displayed value Pulse rate Additional adjustments Temperature unit °C HART mode Standard With this function you can select the mode. ThesensorofferstheHARTmodesstandardandmultidrop. POINTRAC 31 • 8/16 mA/HART - four-wire 35 7 Set up with the display and adjustment module If the measured value is outputted via the 4 … 20 mA output, you must not switch over to HART Multidrop. Themode'Standard',withfixedaddress0(factorysetting),means output of the measured value as 8/16 mA signal. This parameter is described in the operating instructions manual "Display and adjustment module". Additional adjustments - With this function Copy instrument settings • Load parameter adjustment data from the sensor into the display and adjustment module • Write parameter adjustment data from the display and adjustment module into the sensor This parameter is described in the operating instructions manual "Display and adjustment module". Info Info Inthismenuyouwillfindthefollowingmenuitems: • • • • Instrument name - shows instrument name and serial number Instrument version - shows hardware and software version of the instrument Date of manufacture - shows calibration date and the date of the last change Instrument features - shows further instrument features These parameters are described in the operating instructions manual "Display and adjustment module". 7.4 Saving the parameter adjustment data We recommended noting the adjusted data, e.g. in this operating instructions manual, and archiving them afterwards. They are thus available for multiple use or service purposes. If the instrument is equipped with a display and adjustment module, the data in the sensor can be saved in the display and adjustment module. The procedure is described in the operating instructions manual "Display and adjustment module" in the menu item "Copy sensor data". The data remain there permanently even if the sensor power supply fails. The following data or settings for adjustment of the display and adjustment module are saved: • • • All data of the menu "Setup" and "Display" In the menu "Additional adjustments" the items "Sensor-specific units, temperature unit and linearization" The values of the user programmable linearization curve 36 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 The function can also be used to transfer settings from one instrument to another instrument of the same type. If it is necessary to exchange a sensor, the display and adjustment module is inserted into the replacement instrument and the data are likewise written into the sensor via the menu item "Copy sensor data". 8 Setup with PACTware 8 Via the interface adapter directly on the sensor Setup with PACTware 8.1 Connect the PC 2 1 3 Fig. 14: Connection of the PC directly to the sensor via the interface adapter 1 2 3 Information: TheinterfaceadapterVEGACONNECT3isnotsuitableforconnection to the sensor. 5 2 4 CK Connection via HART USB cable to the PC Interface adapter VEGACONNECT 4 ">Sensor N OPE 3 USB TWIST LO 1 43388-EN-131119 Fig. 15: Connecting the PC via HART to the signal cable 1 2 3 4 5 POINTRAC 31 HART resistance 250 Ω (optional depending on processing) Connection cable with 2 mm pins and terminals Processing system/PLC/Voltage supply Voltage supply Necessary components: POINTRAC 31 • 8/16 mA/HART - four-wire 37 8 Setup with PACTware • • • • • POINTRAC 31 PCwithPACTwareandsuitableVEGADTM VEGACONNECT4 HARTresistanceapprox.250Ω Voltagesupply Note: With power supply units with integrated HART resistance (internal resistanceapprox.250Ω),anadditionalexternalresistanceisnot necessary.Thisapplies,e.g.totheVEGAinstrumentsVEGATRENN 149A,VEGAMET381andVEGAMET391).Commerciallyavailable Exseparatorsarealsousuallyequippedwithsufficientcurrentlimitationresistance.Insuchcases,VEGACONNECT4canbeconnected parallel to the 4 … 20 mA cable. Prerequisites 8.2 Parameter adjustment with PACTware For parameter adjustment of the sensor via a Windows PC, the configurationsoftwarePACTwareandasuitableinstrumentdriver(DTM) according to FDT standard are required. The up-to-date PACTware version as well as all available DTMs are compiled in a DTM Collection. The DTMs can also be integrated into other frame applications according to FDT standard. Note: To ensure that all instrument functions are supported, you should always use the latest DTM Collection. Furthermore, not all described functionsareincludedinolderfirmwareversions.Youcandownload the latest instrument software from our homepage. A description of the update procedure is also available in the Internet. Further setup steps are described in the operating instructions manual "DTM Collection/PACTware" attached to each DTM Collection and which can also be downloaded from the Internet. Detailed descriptions are available in the online help of PACTware and the DTMs. 43388-EN-131119 38 POINTRAC 31 • 8/16 mA/HART - four-wire 8 Setup with PACTware Fig. 16: Example of a DTM view Standard/Full version All device DTMs are available as a free-of-charge standard version and as a full version that must be purchased. In the standard version, all functions for complete setup are already included. An assistant for simpleprojectconfigurationsimplifiestheadjustmentconsiderably. Saving/printing the project as well as import/export functions are also part of the standard version. In the full version there is also an extended print function for complete project documentation as well as a save function for measured value and echo curves. In addition, there is a tank calculation program as well as a multiviewer for display and analysis of the saved measured value and echo curves. The standard version is available as a download under www.vega.com/downloads and "Software". The full version is available on CD from the agency serving you. 8.3 Saving the parameter adjustment data 43388-EN-131119 We recommend documenting or saving the parameter adjustment data via PACTware. That way the data are available for multiple use or service purposes. POINTRAC 31 • 8/16 mA/HART - four-wire 39 9 Diagnostics and service 9 Diagnostics and service 9.1 Maintenance If the device is used correctly, no maintenance is required in normal operation. The corresponding source container must be checked in regular intervals.Youcanfindfurtherinformationintheoperatinginstructions manual of the source container. 9.2 Status messages The instrument features self-monitoring and diagnostics according toNE107andVDI/VDE2650.Inadditiontothestatusmessagesin the following tables there are more detailed error messages available under the menu item "Diagnostics" via the display and adjustment module, PACTware/DTM and EDD. Status messages The status messages are divided into the following categories: • • • • Failure Function check Outofspecification Maintenance requirement and explained by pictographs: 1 2 3 4 Fig. 17: Pictographs of the status messages 1 2 3 4 Failure - red Out of specification - yellow Function check - orange Maintenance - blue Failure: Due to a malfunction in the instrument, a failure message is outputted. This status message is always active. It cannot be deactivated by the user. Function check: The instrument is in operation, the measured value is temporarily invalid (for example during simulation). Outofspecification: The measured value is unstable because the instrumentspecificationisexceeded(e.g.electronicstemperature). This status message is inactive by default. It can be activated by the user via PACTware/DTM or EDD. 40 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 This status message is inactive by default. It can be activated by the user via PACTware/DTM or EDD. 9 Diagnostics and service Maintenance:Duetoexternalinfluences,theinstrumentfunction islimited.Themeasurementisaffected,butthemeasuredvalueis still valid. Plan in maintenance for the instrument because a failure is expected in the near future (e.g. due to buildup). This status message is inactive by default. It can be activated by the user via PACTware/DTM or EDD. Failure The following table shows the error codes and text messages in the status message "Failure" and provides information on causes as well as corrective measures. Example for a failure message Code Cause Rectification F008 – Additional sensors not switched on – EMCinfluences – No other sensor available – Check wiring between the sensors – Connect the sensors correctly and make them ready for operation F013 – Error on the current input – No valid measured value – Connected instruments without function – Check current input – Check connected instruments (Slaves) F016 – Valuesofthemin.andmax. – Correct adjustment data adjustment exchanged F017 – The values of the min. and max. adjustment are too close together – Correct adjustment data F025 – Wrong value in the linearization table – Correct linearization table F030 Process value out of limits – Process values are not – Repeat adjustment within the adjusted measuring range F034 – Electronics defective – Exchanging the electronics F035 – Error in the internal instrument communication – Carry out a reset – Exchanging the electronics Text message Error multi sensor communication Sensor signals a fault Adjustment data exchanged Adjustment span too small 43388-EN-131119 Invalid linearization table EPROM hardware error EPROM data error POINTRAC 31 • 8/16 mA/HART - four-wire 41 9 Diagnostics and service Code Cause Rectification F036 – Error during software update – Repeat software update – Exchanging the electronics F037 – Error in RAM – Exchanging the electronics F038 Slave signals failure – Connection cable to the – DefineinstrumentasSlave Slave instrument interrupted – Check the connection cable – Instrumentnotdefinedas to the Slave instrument Slave instrument F040 – Sensor defective F041 – Error in the measured value – Exchanging the electronics recording F045 – Error on the current output – Check wiring of the current output – Exchanging the electronics F052 – Invalid parameter adjustment – Carry out a reset F114 – Discharge accumulator – Readjust real time clock F122 – Instrument addresse was assigned several times – Change instrument addresses F123 X-rayalarm – External instruments cause radioactive radiation – DeterminereasonforX-ray alarm – IncaseofabriefX-ray alarm, shut down the instrument (switching) outputs for this time F124 – Radiation dose too high – Determine reason for increased radiation F125 – Ambient temperature on the housing outside the specification – Cool (heat) the instrument or protect it with isolation material against cold or radiation heat Text message Faulty program memory RAM hardware error Hardware error Photomultiplier error Error on the current output Faultyconfiguration Error real time clock Double address on the multisensor communication bus Ambient temperature too high 42 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Alarm due to increased radiation – Exchanging the electronics 9 Diagnostics and service Function check The following table shows the error codes and text messages in the status message "Function check" and provides information on causes as well as corrective measures. Code Cause Rectification C029 – Simulation active – Finish simulation – Wait for the automatic end after 60 mins. Text message Simulation Outofspecification The following table shows the error codes and text messages in the status message "Out of specification" and provides information on causes as well as corrective measures. Code Cause Rectification S017 – Accuracy outside the specification – Correct adjustment data S025 – Bad linearization table – Carry out linearization S038 – Slaveoutsidethespecifica- – Check Slave tion S125 – Ambient temperature too high/too low Text message Accuracy outside the specification Bad linearization table Slave outside thespecification 43388-EN-131119 Ambient temperature too high/too low – Protect instrument with isolating material against extreme temperatures Maintenance The instrument has no status messages to the section "Maintenance". Reaction when malfunctions occur The operator of the system is responsible for taking suitable measures to rectify faults. Procedure for fault rectification Thefirstmeasuresare: 9.3 • • • Rectify faults Evaluation of fault messages, for example via the display and adjustment module Checking the output signal Treatment of measurement errors Further comprehensive diagnostics options are available with a PC with PACTware and the suitable DTM. In many cases, the reasons can bedeterminedinthiswayandfaultsrectified. POINTRAC 31 • 8/16 mA/HART - four-wire 43 9 Diagnostics and service Check output signal The following table describes possible faults that may not generate an error message: Error Cause Rectification The instrument signals covered without covering with the medium Voltagesupply missing Check cables for breaks; repair if necessary Operating voltage Check, adapt if necessary too low or load resistance too high The instrument signals covered with covering with Electrical connec- Check connection according to tion faulty chapter "Connection steps" and if the medium necessary, correct according to chapter "Wiring plan" Current signal greater than 22 mA or less than 3.6 mA Electronics defective Change the switching behaviour of the sensors under "Diagnosis/Simulation". If the instrument does not switch over, send it in for repair. Buildup on the inner wall of the vessel Remove buildup Electronics module in the sensor defective Note error messages on the display and adjustment module Check the Delta I value. Improve the switching threshold - carry out a double point adjustment Reaction after fault rectification Depending on the reason for the fault and the measures taken, the steps described in chapter "Setup" must be carried out again or must be checked for plausibility and completeness. 24 hour service hotline Should these measures not be successful, please call in urgent cases theVEGAservicehotlineunderthephoneno.+49 1805 858550. The hotline is also available outside normal working hours, seven days a week around the clock. Sinceweofferthisserviceworldwide,thesupportisprovidedin English. The service itself is free of charge, the only costs involved are the normal call charges. 9.4 Exchanging the electronics module Iftheelectronicsmoduleisdefective,itcanbereplacedbyaVEGA service technician. WithSILqualifiedinstrument,onlyarespectiveelectronicsmodule withSILqualificationmustbeused. The new electronics module must be loaded with the default settings of the sensor. These are the options: • • 44 In the factory On site by the service technician POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 In Ex applications, only instruments and electronics modules with appropriate Ex approval may be used. 9 Diagnostics and service 9.5 Software update The following components are required to update the sensor software: • • • • • Sensor Voltagesupply InterfaceadapterVEGACONNECT PC with PACTware Currentsensorsoftwareasfile Youcanfindtheactualsensorsoftwareaswellasdetailedinformation of the procedure under "www.vega.com/downloads" and "Software". Youcanfindinformationabouttheinstallationinthedownloadfile. Caution: Instruments with approvals can be bound to certain software versions.Thereforemakesurethattheapprovalremainseffectivewitha software update. Youcanfinddetailedinformationonwww.vega.com/downloads and "Approvals". 9.6 How to proceed in case of repair The following procedure refers only to the sensor. Should a repair ofthesourcecontainerbenecessary,youcanfindtherespective instructions in the operating instructions manual of the source container. Youcanfindarepairformaswellasdetailedinformationonhowto proceed under www.vega.com/downloads and "Forms and certificates". By doing this you help us carry out the repair quickly and without having to call back for needed information. If a repair is necessary, please proceed as follows: • • • 43388-EN-131119 • Printandfilloutoneformperinstrument Clean the instrument and pack it damage-proof Attach the completed form and, if need be, also a safety data sheet outside on the packaging Please contact the agency serving you to get the address for thereturnshipment.Youcanfindtheagencyonourhomepage www.vega.com. POINTRAC 31 • 8/16 mA/HART - four-wire 45 10 Dismounting 10 Dismounting 10.1 Dismounting steps Warning: Before dismounting, be aware of dangerous process conditions such as e.g. pressure in the vessel or pipeline, high temperatures, corrosive or toxic products etc. Take note of chapters "Mounting" and "Connecting to power supply" and carry out the listed steps in reverse order. 10.2 Disposal The instrument consists of materials which can be recycled by specialised recycling companies. We use recyclable materials and have designed the parts to be easily separable. Correctdisposalavoidsnegativeeffectsonhumansandtheenvironment and ensures recycling of useful raw materials. Materials: see chapter "Technical data" If you have no way to dispose of the old instrument properly, please contact us concerning return and disposal. WEEE directive 2002/96/EG This instrument is not subject to the WEEE directive 2002/96/EG and the respective national laws. Pass the instrument directly on to a specialised recycling company and do not use the municipal collecting points. These may be used only for privately used products according to the WEEE directive. 43388-EN-131119 46 POINTRAC 31 • 8/16 mA/HART - four-wire 11 Supplement 11 Supplement 11.1 Technical data General data 316L corresponds to 1.4404 or 1.4435 Materials, non-wetted parts Ʋ Detector tube Ʋ Scintillation material Ʋ Aluminium die-casting housing Ʋ Stainless steel housing Ʋ Seal between housing and housing cover Ʋ Inspection window in housing cover (optional) Ʋ Ground terminal 316L PVT(Polyvinyltoluene) Aluminium die-casting AlSi10Mg, powder-coated - basis: Polyester 316L NBR (stainless steel housing, investment casting), silicone (Aluminium housing) Polycarbonate 316L Ʋ Mounting accessory 316L Ʋ Fastening lugs ø 9 mm (0.35 in), hole centre distance 119 mm (4.69 in) Ʋ Aluminium housing, with electronics 3.4 kg (7.5 lbs) + measuring length Ʋ Measuring length 152 mm (6 in) 0.98 kg (2.16 lbs) Processfittings Weight Ʋ Stainless steel housing, with electron- 8.36 kg (18.43 lbs) + measuring length ics Ʋ Measuring length 304 mm (12 in) 1.95 kg (4.3 lbs) Max. torque, mounting screws - fastening 50 Nm (36.88 lbf ft) lugs on the sensor housing Max. torque for NPT cable glands and Conduit tubes Ʋ Aluminium/Stainless steel housing The measured variable is the intensity of the gamma radiation. When the intensity of the radiation is below the stipulated value due to a damping by the medium, the POINTRAC 31 switches. 43388-EN-131119 Input variable Measured variable 50 Nm (36.88 lbf ft) POINTRAC 31 • 8/16 mA/HART - four-wire 47 L 11 Supplement Fig. 18: Data of the input variable L Measuring range (range in which the switching point must lie) Measuring range Analogue input Ʋ Input type Ʋ Internal load Switching input Ʋ Type of input - Open Collector Ʋ Type of input - Relay contact 152 mm (6 in) or 304 mm (12 in) 4 … 20 mA, passive 250Ω 10 mA 100 mA Output variable Output signals 8/16 mA/HART - active; 8/16 mA/HART - Multidrop Shortcircuit protection Available Terminal voltage passive Potential separation 9…30VDC Available Failure signal current output (adjustable) 22 mA, < 3.6 mA Max. output current Starting current Load Ʋ 8/16 mA/HART - active Ʋ 8/16 mA/HART - intrinsically safe HART output values Ʋ PV(PrimaryValue) Ʋ SV(SecondaryValue) 48 ≤3.6mA <500Ω <300Ω Is calculated automatically by the instrument Switching status Electronics temperature POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Damping (63 % of the input variable) 22 mA 11 Supplement Relay output Output Switching voltage Ʋ Min. Ʋ Max. Switching current Ʋ Min. Ʋ Max. Breaking capacity Ʋ Min. Ʋ Max. Contact material (relay contacts) Relayoutput(SPDT),floatingspdt 10mV 253VAC,253VDC 10 µA 3 A AC, 1 A DC 50 mW 750VAAC,40WDC If inductive loads or stronger currents are switched through, the gold plating on the relay contact surface will be permanently damaged. The contact is then no longer suitable for switching low-level signal circuits. AgNi or AgSnO and Au plated Accuracy (according to DIN EN 60770-1) Process reference conditions according to DIN EN 61298-1 Ʋ Temperature Ʋ Relative humidity Ʋ Air pressure Repeatability Deviation with bulk solids DeviationunderEMCinfluence +18…+30°C(+64…+86°F) 45 … 75 % 860 … 1060 mbar/86 … 106 kPa (12.5 … 15.4 psig) ≤0.5% The values depend to a great extent on the application. Bindingspecificationsarethusnotpossible. ≤1% Variablesinfluencingmeasurementaccuracy Specificationsapplyalsotothecurrentoutput Temperature drift - Current output Deviation on the current output through analogue/digital conversion Deviation on the current output due to strong, high frequency electromagnetic interference acc. to EN 61326 ±0.03 %/10 K relating to the 16 mA span max. ±0.3 % <±15 µA <±150 µA 43388-EN-131119 Ambient conditions Ambient, storage and transport tempera- -40…+60°C(-40…+140°F) ture Process conditions Fortheprocessconditions,pleasealsonotethespecificationsonthetypelabel.Thelowervalue always applies. Process pressure Unpressurized POINTRAC 31 • 8/16 mA/HART - four-wire 49 11 Supplement Process temperature (measured on the detector tube) -40…+60°C(-40…+140°F) Vibrationresistance3) mechanical vibrations up to 1 g in the frequency range 5 … 200 Hz Withtemperaturesofmorethan60°Cwerecommend the use of water cooling Electromechanical data - version IP 66/IP 67 Cable entry Ʋ M20 x 1.5 2 x cable gland M20 x 1.5 (cable: ø 6 … 12 mm), 4 x blind plug M20 x 1.5 Ʋ ½ NPT 5 x closing cap (red) ½ NPT Included: 1 x cable gland M20 x 1.5 Included: 3 x cable gland ½ NPT (cable: ø 6 … 12 mm), 4 x blind plug ½ NPT Spring-loaded terminals for wire cross-section Ʋ Massive wire, cord Ʋ Stranded wire with end sleeve Display and adjustment module Display element Measured value indication Ʋ Number of digits Ʋ Size of digits Adjustment elements Protection rating Ʋ unassembled Ʋ mounted into the housing without cover Materials Ʋ Housing Ʋ Inspection window 0.2 … 2.5 mm² (AWG 24 … 14) 0.2 … 1.5 mm² (AWG 24 … 16) Display with backlight 5 W x H = 7 x 13 mm 4 keys IP 20 IP 40 ABS Polyester foil Integrated clock Date format Day.Month.Year Time zone Ex factory CET Time format Rate deviation max. 12 h/24 h 10.5 min/year Accuracy 3) 50 ±1°C(1.8°F) Tested according to the guidelines of German Lloyd, GL directive 2. POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Measurement electronics temerature Resolution 1°C(1.8°F) 11 Supplement Voltage supply Operating voltage 20…72VDCor20…253VAC,50/60Hz Max. power consumption 6VA(AC);4W(DC) Interpolation protection Available Electrical protective measures Protection, depending on housing version IP 66/IP 674) Protection class I Overvoltage category III Approvals Instrumentswithapprovalscanhavedifferenttechnicaldatadependingontheversion. For that reason the associated approval documents of these instruments must be carefully noted. They are part of the delivery or can be downloaded under www.vega.com and "VEGA Tools" as well as under "Downloads" and "Approvals". 11.2 Dimensions 43388-EN-131119 The following dimensional drawings represent only an extract of all possible versions. Detailed dimensional drawings can be downloaded at www.vega.com/downloads under "Drawings". 4) A suitable cable is the prerequisite for maintaining the protection rating. POINTRAC 31 • 8/16 mA/HART - four-wire 51 11 Supplement 9 mm (0.35") Aluminium and stainless steel housing 119 mm (4.69") M20x1,5/ ½ NPT 169 mm (6.65") 116,5 mm (4.59") 242,5 mm (9.55") 54,5 mm (2.15") 9 mm (0.35") 175 mm (6.89") 90 mm (3.54") 143,5 mm (5.65") 100 mm (3.94") Fig. 19: Aluminium housing or stainless steel housing - Precision casting 43388-EN-131119 52 POINTRAC 31 • 8/16 mA/HART - four-wire 11 Supplement 22 mm (0.87") 242,5 mm (9.55") POINTRAC 31 36 mm (1.42") L ø 76,2 mm (3") Fig. 20: POINTRAC 31 Measuring range = Order length 152 mm or 304 mm (6 in/12 in) 43388-EN-131119 L POINTRAC 31 • 8/16 mA/HART - four-wire 53 11 Supplement POINTRAC 31 - Mounting example 220 mm (8.66") 101,6 mm (4.00") 101,3 mm (4.00") 70 mm (2.76") 5 mm (0.20") 36 mm (1.42") 195 mm (7.68") 152,5 mm (6.00") 54 mm (2.13") 51 mm (2.01") 14 mm (0.55") 31,8 mm (1.5") 38 mm (1.50") 183 mm (7.20") 38 mm (1.50") 127 mm (5.00") 14,3 mm (0.56") Fig. 21: POINTRAC 31 with supplied mounting accessories 43388-EN-131119 54 POINTRAC 31 • 8/16 mA/HART - four-wire 11 Supplement 11.3 Industrial property rights VEGA product lines are global protected by industrial property rights. Further information see www.vega.com. Only in U.S.A.: Further information see patent label at the sensor housing. VEGA Produktfamilien sind weltweit geschützt durch gewerbliche Schutzrechte. Nähere Informationen unter www.vega.com. Les lignes de produits VEGA sont globalement protégées par des droits de propriété intellectuelle. Pour plus d'informations, on pourra se référer au site www.vega.com. VEGA lineas de productos están protegidas por los derechos en el campo de la propiedad industrial. Para mayor información revise la pagina web www.vega.com. Линии продукции фирмы ВЕГА защищаются по всему миру правами на интеллектуальную собственность. Дальнейшую информацию смотрите на сайте www.vega.com. VEGA系列产品在全球享有知识产权保护。 进一步信息请参见网站<www.vega.com>。 11.4 Trademark 43388-EN-131119 All the brands as well as trade and company names used are property of their lawful proprietor/ originator. POINTRAC 31 • 8/16 mA/HART - four-wire 55 INDEX INDEX A Accessories – External indicating unit 10 Adjustment – System 25 Adjustment data 33 Adjustment mode 28 Adjustment point 29 Application 28 B Background radiation 28 Block adjustment 26, 32 C Cable entry 16 Check signal 44 Connection cable 16 Connection procedure 17 Connection technology 17 Control areas 11 Current output 31 Current output mode 31 D Damping 34 Date 34 Date of manufacture 36 Default values 35 Delta I 29 Device name 36 Device settings Copy 36 Displayed value 33 I Installation position 13 Instrument features 36 Instrument version 36 Isotope – Co-60 27 – Cs-137 27 L Language 32 M Main menu 26 Mode 35 N NAMUR NE 107 – Failure 41 – Function check 43 – Maintenance 43 – Outofspecification43 P Peak value indicator 33 PIN 34 Potential equalisation 17 Protection class 16 R Emitter 27 Radiation protection 11 Radiationsafetyofficer11 Relay 31 Repair 45 Replacement parts – Electronics module 10 Reset 34 F S E Faultrectification43 Functional principle 8 G Grounding 16 Handling permit 11 HART 35 Heat 15 56 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 H Sensor orientation 14 Sensor status 33 Service – Hotline 44 Setup – Extended adjustment 26 Shielding 16 Simulation 33 Source container 10 Status messages - NAMUR NE 107 40 INDEX T Time 34 Type plate 7 U Unit 28 V Voltagesupply16, 51 W 43388-EN-131119 Water cooling 15 POINTRAC 31 • 8/16 mA/HART - four-wire 57 Notes 43388-EN-131119 58 POINTRAC 31 • 8/16 mA/HART - four-wire 43388-EN-131119 Notes POINTRAC 31 • 8/16 mA/HART - four-wire 59 All statements concerning scope of delivery, application, practical use and operating conditions of the sensors and processing systems correspond to the information available at the time of printing. Subject to change without prior notice © VEGA Grieshaber KG, Schiltach/Germany 2013 VEGA Grieshaber KG Am Hohenstein 113 77761 Schiltach Germany Phone +49 7836 50-0 Fax +49 7836 50-201 E-mail: [email protected] www.vega.com 43388-EN-131119 Printing date: